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19. STARTER SYSTEM
19-0
MXU 500
19
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STARTER
SYSTEM__________________________________________________________________________________
STARTING SYSTEM LAYOUT -----------------------------------------
19- 1STARTING CIRCUIT
------------------------------------------------------ 19- 2SERVICE
INFORMATION------------------------------------------------ 19-
3TROUBLESHOOTING-----------------------------------------------------
19- 3STARTER MOTOR
--------------------------------------------------------- 19-
6STARTER RELAY SWITCH/STARTER MAG ----------------------- 19-
7RECOIL STARTER REMOVAL/INSPECTION/INSTALLATION
------------------------------------------------------------ 19-
9RECOIL STARTER HANDLE REPLACE ------------------------------
19-11RECOIL STARTER
DISASSEMBLY/INSPECTION/ASSEMBLY------------------------------------------------------------------
19-12STARTER PULLEY REMOVAL/INSPECTION/INSTALLATION
------------------------------------------------------------
19-18STARTER CLUTCH REMOVAL/INSPECTION/INSTALLATION
------------------------------------------------------------
19-20
19
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19. STARTER SYSTEM
19-1
MXU 500
STARTING SYSTEM LAYOUT
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19. STARTER SYSTEM
19-2
MXU 500
STARTING CIRCUIT
(ON ROAD)
(OFF ROAD)
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19. STARTER SYSTEM
19-3
MXU 500
SERVICE INFORMATION
GENERAL• Always turn the ignition switch to “OFF” before
servicing the starter motor. The motor could
suddenly start, causing serious injury.• The starter motor can
be serviced with the engine in the frame.• When checking the
starter system, always follow the steps in the troubleshooting flow
chart
(page 19-2).• A weak battery may be unable to turn the starter
motor quickly enough, or supply adequate
ignition current.• If the current is kept flowing through the
starter motor to turn it while the engine is not cranking
over, the starter motor may be damaged.• See section 20 for
following components:
ä Ignition switchä Starter switchä Brake light switch
SPECIAL TOOLFlywheel puller A120E00060
TORQUEStarter pulley nut 5.5 kgf-m (55 N-m, 40 lbf-ft)
TROUBLESHOOTING
• Check for the following before troubleshooting: ─ Blown main
fuse (30A) and sub fuse (15 A) ─ Loose battery and starter motor
cable ─ Discharged battery• The starter motor can turn with the
following conditions: ─ Ignition switch ON ─ Engine stop switch in
RUN (OFF ROAD) ─ Rear brake lever fully squeezed
─ Starter switch pushed
Starter motor will not turn
•Poorly connected battery terminals.•Open or short circuit in
battery.
(Go to following page)
Check for loose or poorlyconnected battery terminalsand opened
or shorted batterycable.
Abnormal
Normal
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19. STARTER SYSTEM
19-4
MXU 500
(From previous page)
•Poorly connected terminal
•Poorly connected starter motor cable.•Open circuit in starter
motor cable.
•Faulty starter motor.
•Loose or disconnected starter motor cable.•Faulty starter
MAG.
•Faulty brake light switch.•Loose or poor contact of
connector.•Open or short circuit in wire harness.
(Go to following page)
Abnormal
Starter motordoes not turn
Normal
Abnormal
Normal
Check for loose or poorlyconnected starter MAGterminals.
AbnormalCheck for loose or poorlyconnected or broken
startermotor cable.
No clicks
ClicksWith the ignition switchturned to “ON”, push thestarter
switch and check for aclick sound from the starterMAG.
Connect the starter motor terminaldirectly to the battery
positiveterminal (Because a large amount ofcurrent flows, do not
use a thin wire).
Starter motor turns
Normal
Check the starter relay coilground line (page 19-6)
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19. STARTER SYSTEM
19-5
MXU 500
(From previous page)
•Faulty engine stop switch (OFF ROAD).•Faulty starter
switch.•Loose or poor contact of connector.•Open circuit in wire
harness.
•Faulty starter MAG.
•Loose or poor starter relay connector contact.
Battery voltage registers
No voltageCheck the starter MAGvoltage (page 19-7).
AbnormalCheck the starter relay for aclick sound from the
starterrelay. (page 19-6).
Normal
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19. STARTER SYSTEM
19-6
MXU 500
STARTER MOTOR
INSPECTION
Disconnect the starter motor cable from thestarter MAG.Turn the
ignition switch to “ON”.Connect the starter motor cable directly to
thebattery positive terminal.If the starter motor does not turn,
the startermotor is faulty.
REMOVAL
Remove the carburetor (refer to the“CARBURETOR
REMOVAL/CHOKEINSPECTION/INSTALLATION” sectionin the chapter 5).
Turn the ignition switch turned to “OFF”
Remove the two mounting bolts and startermotor.
Release the rubber cap and remove theterminal nut to disconnect
the starter motorcable from the starter motor.
INSTALLATION
Coat a new O-ring with engine oil and installit into the starter
motor groove.
Connect the starter motor cable to motorterminal with the
terminal nut and tighten it.
Install the starter motor into the crankcase.
Install the two mounting bolts and tighten themsecurely.
Bolts Nut
Rubber Cap
O-ring
Starter Motor Cable
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19. STARTER SYSTEM
19-7
MXU 500
STARTER RELAYSWITCH/STARTER MAG
INSPECTION
Turn the ignition switch to “ON”.
Squeeze the brake lever or pedal fully.The coil is normal if the
starter relay switchclicks.
Squeeze and hold the brake lever or pedalfully then push the
starter switch.The coil is normal if the starter MAG
switchclicks.
If you do not hear the switch click. Inspectthe relay switch and
starter MAG using theprocedure below.
GROUND LINE INSPECTION
Disconnect the starter relay switch connector.Check for
continuity between the Green wireterminal and ground.
There should be continuity.
VOLTAGE INSPECTION
Connect the starter MAG connector.Turn the ignition switch
ON.
Measure the starter MAG Yellow/Red wireterminal and ground.
If the battery voltage appears only when therear brake lever is
squeezed fully (or the gearchange switch in neutral) and starter
switch ispushed, the circuit is normal.
Starter MAG
Starter Relay
Starter MAG
Starter Relay
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19. STARTER SYSTEM
19-8
MXU 500
CONTINUTY INSPECTION
Disconnect the starter MAG switch connectorand cables.Connect a
fully charged 12 V battery positivewire to the relay switch
Yellow/Red wireterminal and negative wire to theYellow/Green wire
terminal.
There should be continuity between the cableterminals while the
battery is connected, andno continuity when the battery
isdisconnected.
Starter MAG
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19. STARTER SYSTEM
19-9
MXU 500
RECOIL STARTERREMOVAL/INSPECTION/INSTALLATION
REMOVAL
Remove the six bolts, then remove the recoilstarter
assembly.
Remove the two dowel pins.
INSTALLATION
Install the dowel pins.
Recoil Starter
Dowel Pins
Dowel Pins
The recoil starter can not start theengine when the battery is
removal.
＊
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19. STARTER SYSTEM
19-10
MXU 500
Install the recoil starter assembly.Install and tighten the six
bolts diagonally.
Recoil Starter
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19. STARTER SYSTEM
19-11
MXU 500
RECOIL STARTER HANDLEREPLACE
Remove the recoil starter assembly (refer tothe “RECOIL
STARTERREMOVAL/INSPECTION/INSTALLATION” section in this
chapter).
Remove the cap on the handle.
Replace the handle.
Cap
Knot
Knot Collar Handle
Before untying the knot above thestarter handle, make a knot in
the ropeso that the rope is not pulled into thehousing.
＊
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19. STARTER SYSTEM
19-12
MXU 500
RECOIL STARTERDISASSEMBLY/INSPECTION/ASSEMBLY
DISASSEMBLY
Remove the recoil starter assembly (refer tothe “RECOIL
STARTERREMOVAL/INSPECTION/INSTALLATION” section in this
chapter).
Remove the handle (refer to the “RECOILSTARTER HANDLE REPLACE”
sectionin this chapter).
Untying the knot, then turn the reel clockwisewith the rope
slowly.
Remove the bolt and then remove the washer,friction plate and
pawl spring.
Knot
Bolt/Washer/Plate/Spring
Rope
Reel
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19. STARTER SYSTEM
19-13
MXU 500
Remove the reel, then remove the coil spring.
INSPECTION
Pull the rope and check that the ratchet ispushed out.
Inspect the rope, reel and drive pawl for wearor damage.
Inspect the pawl spring for fatigue.
Coil Spring
Reel
Wear hand and eye protection whenremoving the reel, since the
spring mayquickly unwind and cause and injury.
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Pawl Spring Drive Pawls
Reel Rope
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19. STARTER SYSTEM
19-14
MXU 500
Inspect the coil spring for fatigue.
ASSEMBLY
Apply molybdenum disulfide grease to thecoil spring, then
install the coil spring.
Pass the rope through the reel and make aknot above the
reel.
Coil Spring
Reel
Knot Rope
Hook
Coil Spring
● Wear hand and eye protection wheninstalling the spring, since
the springmay quickly unwind and cause andinjury.
● Mesh the spring hook with thehousing slit, then wind the
housing tomake the diameter of the springsmaller and the spring
will be into thehousing.
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19. STARTER SYSTEM
19-15
MXU 500
Install the reel.
Hook the rope onto the hook part of the reel,then pass the rope
through the recoil starterhousing, handle and collar.Make a knot
above the collar.
Hook the rope onto the hook part of the reel,turn the reel
counterclockwise three or fourtimes with the rope.
Coil Spring
Reel
● Wear hand and eye protection wheninstalling the reel, since
the springmay quickly unwind and cause andinjury.
● Engage the part of the reel with coilspring end.
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Housing Collar Knot
Handle
Wear hand and eye protection whenassembling the recoil starter,
since thespring may quickly unwind and causeand injury.
＊
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19. STARTER SYSTEM
19-16
MXU 500
Unhook the rope, then turn the reel clockwisewith the rope
slowly.
Apply molybdenum disulfide grease to thewasher and friction
plate.
Install the pawl spring, friction plate/washer.Install and
tighten the new bolt securely.
Apply Grease Apply Grease
Spring
Bolt/Washer/Plate/Spring
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19. STARTER SYSTEM
19-17
MXU 500
Pull the rope and check that the ratchet ispushed out.
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19. STARTER SYSTEM
19-18
MXU 500
STARTER PULLEYREMOVAL/INSPECTION/INSTALLATION
REMOVAL
Remove the recoil starter assembly (refer tothe “RECOIL
STARTERREMOVAL/INSPECTION/INSTALLATION” section in this
chapter).
Remove the starter pulley nut by using asuitable bar.
INSPECTION
Inspect the starter pulley for cracks or pitting.Inspect the
O-ring for wear or damage.
Inspect the oil stop ring for crack or damage.
Nut/Washer
Oil Stop Ring
O-ring
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19. STARTER SYSTEM
19-19
MXU 500
INSTALLATION
Install the starter pulley and washer.Install and tighten the
nut to the specifiedtorque by using suitable bar.
Torque: 5.5 kgf-m (55 N-m, 40 lbf-ft)
Nut/Washer
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19. STARTER SYSTEM
19-20
MXU 500
STARTER CLUTCHREMOVAL/INSPECTION/INSTALLATION
REMVOAL
Remove the right crankcase cover (refer tothe “ALTERNATOR
STATORREMOVAL/INSPECTION/INSTALLATION” section in the
chapter17).
Remove the flywheel/driven gear by usingthe special tool.
Special tool:Flywheel puller A120E00060
Remove the woodruff key.
Remove the reduction gear.
Flywheel Puller
Flywheel/Driven Gear
Woodruff Key
Reduction Gear
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19. STARTER SYSTEM
19-21
MXU 500
INSPECTION
Check the operation of the sprag clutch byturning the driven
gear.You should be able to turn the driven gearclockwise smoothly,
but the gear should notturn counterclockwise.
Remove the starter driven gear by turning thedriven gear.
Check the starter driven gear teeth for wear ordamage.
Measure the starter driven gear boss O.D..
Service limit: 57.7 mm (2.272 in)
Measure the starter driven gear bushing I.D..
Service limit: 27.1 mm (1.084 in)
Check the starter reduction gear teeth andshaft for wear or
damage.
Reduction Gear
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19. STARTER SYSTEM
19-22
MXU 500
INSTALLATION
Apply oil to the starter reduction gear.Install the starter
reduction gear to the rightcrankcase.
Install the woodruff key in the crankshaft keygroove.
Apply molybdenum oil solution to the starterdriven gear
bushing.Install the starter driven gear by turning thedriven gear
clockwise.
Reduction Gear
Woodruff Key
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19. STARTER SYSTEM
19-23
MXU 500
Clean any oil from the tappered portion of theflywheel I.D.
Install the flywheel/driven gear onto thecrankshaft, aligning
the key way withwoodruff key.
Flywheel
Reduction Gear Driven Gear
